Vibrational reduction system for automotive vehicles

ABSTRACT

A vibration reduction and damping system for use in automotive closure panels, such as doors, lift gates, or other operable hatches comprising an intrusion device and an expandable material, such as a polymer-based foam, disposed along at lease a surface of the intrusion device prior to final assembly of the vehicle by the vehicle manufacturer. The system is activated as the vehicle undergoes the final vehicle assembly process, which activates and transforms the expandable material, preferably during an automobile paint operation, to expand, bond and fill the door assembly structure for vibrational damping and noise reduction.

FIELD OF THE INVENTION

[0001] The present invention relates generally to improved methods andsystems for reducing noise and vibration characteristics in anautomotive vehicle. More particularly, the invention relates to ananti-vibration damping material or pellet application system integratedalong portions of automotive closure panels, such as portions of anautomotive door frame or other panel assembly used to facilitatepassenger or cargo ingress/egress to the vehicle. The present inventionis applied to selected portions of an automotive vehicle throughextrusion techniques resulting in the reduction of vibration and theimprovement of sound absorption characteristics of the automotivevehicle.

BACKGROUND OF THE INVENTION

[0002] Traditional automotive panel assembly operations generallyrequire a specific pre-assembly manufacturing step or process, whichoccurs prior to final assembly of the vehicle. Typically for automotivedoor assemblies, this step or process involves the application ofchemical compositions to a traditional door intrusion beam after thebeam is shipped to the vehicle manufacturer from the intrusion devicesupplier. This process requires the vehicle manufacturer to allocatetooling and manufacturing facilities for the intrusion deviceapplication at either a separate stamping facility where the door isassembled or in the final vehicle assembly plant. One such techniqueemploys the use of pumpable products applied to the intrusion device inthe form of “wet” compositions, which can remain tacky or may otherwisebe applied to the beam in a non-uniform manner. For instance, onepopular technique utilizes a pumpable product consisting of a thermallyactivated polymeric material, which upon heat activation expands andfills the space defined between the intrusion device and the outer doorpanel.

[0003] While these prior art system perform well and are advantageous inmany circumstances, they often require a large capital investment tointegrate the pumpable product into the chosen manufacturing facility,utilize a large amount of floor space and maintenance clean-up resourcesat the stamping facility or vehicle assembly plant, and require anadditional manufacturing process and labor demand. In turn, themanufacturer is required to devote both financial and technicalresources to develop tooling for the pumpable product as well astransportation costs, which adds potential cost and delay, particularlyif changes to the vehicle structure are implemented during the designstages.

[0004] Accordingly, there is need for a simple low cost system thatprovides an integrated anti-vibration damping material, in the form of a“dry” chemical product which can be extruded-in-place within targetedportions of an automotive panel assembly to reduce vibrationcharacteristics and which can be employed across a wide range ofdifferent sizes or shapes of cavities found in automotive vehicles.

SUMMARY OF THE INVENTION

[0005] The present invention is directed to a vibration reductionsystem, and particularly one for automotive frame assemblies, such as(without limitation) vehicle door frame assemblies having a doorintrusion device as well as any other automotive closure panelassemblies used in sliding doors, lift gates, or other designs used tofacilitate the ingress and egress of passengers and/or cargo to anautomotive vehicle. The system generally employs extrusion techniques inthe form of a mini-applicator technology for facilitating theapplication of a dry chemical, anti-vibration damping material onto theintrusion device and/or other selected portion of the door frame, suchas the belt line reinforcement, through an extrude-in-place process. Itis contemplated that the material disclosed in the present inventionfunctions as an anti-vibration dampener when expanded and bonded to thedoor intrusion device and optionally the inner and outer body panels,when the intrusion device, such as a intrusion device (now attached tothe vehicle in the assembly operation), is processed through paintoperations and process cycles typically encountered in a vehicleassembly plant. In one embodiment, the material is heat expandable andat least partially fills the cavity by cross-linking the door intrusiondevice and the inner and outer door panel during the painting operationthereby reducing noise and vibration characteristics of the vehicle aswell as producing a more quiet door assembly when the vehicle door isopened and closed. In another embodiment, the material is a melt-flowmaterial, and upon the application of heat will spread over a surface.

[0006] The present invention further serves to eliminate cleanliness andmaintenance issues typically encountered through the use of a pumpableproduct process or application of “wet” chemical technology in either apre-assembly stamping facility or a vehicle assembly plant since theanti-vibration damping material can be extruded or mini-applicationbonded onto the door intrusion device prior to paint operationprocessing. Hence, the present invention can be utilized by either thedoor intrusion device manufacturer or the vehicle manufacturer andextruded onto the door intrusion device itself for use by the vehiclemanufacturer in the final assembly operation.

[0007] In a particular preferred embodiment, the damping material ormedium comprises a plurality of pellets or a bead that is extruded alongand onto portions of the intrusion device in a solid (though pliable)form in accordance with the teachings of commonly owned U.S. Pat. No.5,358,397 (“Apparatus For Extruding Flowable Materials”), herebyexpressly incorporated by reference, such type of apparatus beingreferred to herein as a “min-applicator.” A preferred mini-applicator isan extrude-in-place device suitable for extrusion with or withoutrobotic assistance, and which may be portable or remain stationary in apredetermined location. The use of a mini-applicator advantageouslyallows extrusion of meltable plastic materials of various section sizesor shapes directly at production or assembly lines. The material ormedium is at least partially coated with an active polymer havingdamping characteristics or other heat activated polymer, (e.g., aformable hot melt adhesive based polymer or an expandable structuralfoam, examples of which include olefinic polymers, vinyl polymers,polyamides, EVA's, thermoplastic adhesives, thermoplasticrubber-containing polymers, epoxies, urethanes or the like). The pelletthen expands and bonds to the intrusion device and the body panel whenexposed to the e-coat process as well as other paint operation cyclesencountered in a final vehicle assembly facility. In addition, it iscontemplated that the present invention may utilize an application ofexpandable material directly to a structural member or trim component ofan automotive vehicle in an automated or otherwise expeditedmanufacturing process which may involve heating through traditionalmethods as well as welding and radiation curable technology or cleaningthe selected member or part prior to application to assist in adhesionof the expandable material.

[0008] In a particular non-limiting embodiment, a plurality of pelletscomprised of the vibration damping material or medium are transformedfrom a solid or dry chemical state to a visco-elastic stage through theuse of a suitable mini-applicator which processes the pellets at atemperature sufficient to transform the pellets into a visco-elasticelastic material capable of flowing onto the external surface of aintrusion device in a desired consistency, thickness, and pattern.

[0009] The heat application and other shear functions from themini-applicator allows the material to flow in a uniform shape andmanner as it is extruded onto an external surface of the intrusiondevice, such as a door intrusion beam, where it bonds. Once applied tothe external surface of the intrusion device by the mini-applicator andno longer exposed to the heat source emanating from the mini-applicator,the material returns to it solid or dry chemical state and therebyremains disposed in place along the selected portion of the intrusiondevice. The intrusion device is then mounted within an automotive doorassembly or other panel assembly by the vehicle manufacture inaccordance with manufacturing techniques that are well known in the art.As the assembly is prepared for final assembly of the vehicle, it isprocessed through e-coat or other heat-inducing paint operations whichresult in expansion and bonding of the material from the intrusiondevice to either or both of the outer panel or the inner panel of theselected automotive closure panel, such as a door frame assembly havingan inner door panel and an outer door panel, where it cures and remainsin place. It is contemplated that the material expands from the externalsurface of the intrusion device and cross-links to the substrates, whichcan comprise either of both of a door inner panel and the door outerpanel, thereby serving to reduce the noise and vibration emanating fromthe door assembly. Although the preferred embodiment discloses thematerial essentially chemically cross-linking from the external surfaceof an intrusion device, such as a door intrusion beam, into contact withthe door outer panel, it will be appreciated that various patterns andapplications of the material along the intrusion device would allow thematerial to expand and chemically cross-link with either or both of thedoor inner panel and door outer panel as well as any other substratethat may be utilized or encountered in a door assembly or otherapplication which would facilitate either passenger of cargo access to avehicle.

[0010] In one embodiment the vibration reducing medium isextruded-in-place onto an intrusion device in a continuous ornon-continuous extrusion adjacent to one or more inner walls defining acavity within an automotive door assembly. The vibration reducing mediumis activated to accomplish transformation (e.g., expansion or flow) ofthe active polymer or polymer within the cavity after the door assemblyis mounted onto the vehicle and the vehicle is exposed to heat as it isprocessed through the e-coat coat and paint operation cycles of a finalautomotive assembly plant, which is well known in the art. The resultingstructure includes a wall or expansive extrusion that is coated over atleast a portion of its surface with the vibration reducing medium actingto reduce vibration during transport and during functional operation ofthe door assembly. It will be appreciated that a preferred vibrationreduction medium would consist of a damping material comprising a numberof chemical formulations including, but not limited to, metal (such assteel, aluminum, etc.), rubber (such as a butyl or isobutylene polymer,copolymer, or similar elastomer having good damping characteristics),and plastic polymer chemistry (ideally material that would remain rigidat temperatures generally encountered by an automotive body skin duringoperation of the vehicle, for example −40° C. to 190° C.

DESCRIPTION OF THE DRAWINGS

[0011] The features and inventive aspects of the present invention willbecome more apparent upon reading the following detailed description,claims, and drawings, of which the following is a brief description:

[0012]FIG. 1 is a cutaway plan view of a vehicle door assembly with avibration reducing material extruded-in-place with continuous extrusionin accordance with the present invention prior to activation of thematerial.

[0013]FIG. 2 is a cutaway plan view of a vehicle door assembly with avibration reducing material extruded-in-place with non-continuousextrusion in accordance with the present invention prior to activationof the material.

[0014]FIG. 3 is a cutaway plan view of a vehicle door assembly utilizingthe vibration reducing material of the present invention applied toselected portions of the door frame assembly, including the belt-linereinforcement member.

DESCRIPTION OF PREFERRED EMBODIMENT

[0015]FIG. 1 illustrates an example of an automotive door frame assembly10 typically encountered in the manufacture of automotive vehicles whichincludes a door intrusion device 12. As will be appreciated, it iscommon for such structures to include a plurality of hollow-portionedpanel members that are joined and shaped to define the door inner panel14, within which there are cavities. As will be recognized, examples ofa suitable door frame assembly 10 may include cargo doors, lift gates,hatchbacks, sliding doors, easy access third doors, door handles, locks,window assemblies or other vehicle doors and door components, sub-frameconstruction, or the like. One such structure in FIG. 1, for purposes ofillustration (without limitation) includes a door intrusion device 12which may be in the form of a door intrusion beam. Although the presentinvention may be used in other portions of a door frame assembly 10 thatdo not require the presence of a door intrusion device 12 as well asother automotive closure panel assemblies other than doors, theintrusion device 12 is typically comprised of metal (e.g., steel,aluminum, magnesium based, or the like) and may be cold stamped, hotstamped, roll-formed, a tubular beam, a hollow tubular beam, or ahydroformed section. It is also contemplated that the intrusion device12 could be formed of composite or other high strength polymericmaterials depending upon the structural reinforcement required forspecific applications of the present invention.

[0016] As stated, it is contemplated that a variety of automotiveclosure panel applications may be treated in accordance with the presentinvention. In FIG. 1 there is shown a portion of the frame assembly 10that comprises an intrusion device 12 which bridges the assembly 10 at afirst end 16 and a second end 17, the frame 10 assembly thereby definingthe door panel compartment. As illustrated in the cutaway view of FIG.1, the door intrusion device 12 is generally tubular and assists in thereinforcement of the assembly 10 with suitable cross sectionalconfiguration or reinforcements depending upon the size or configurationof the particular application. The intrusion device 12 itself might behollow and further reinforced, using technology such as that disclosedin U.S. Pat. Nos. 4,922,596, 4,978,562, 5,124,186, and 5,884,960 andcommonly owned, co-pending U.S. application Ser. Nos. 09/502,686 filedFeb. 11, 2000 and Ser. No. 09/524,961 filed Mar. 14, 2000, all of whichare expressly incorporated by reference.

[0017] Vibration reduction of the assembly and door intrusion device 12is accomplished according to the present invention by anextrusion-in-place or mini-extrusion application of an appropriatepattern 18 of a vibration reduction material 20 of the type discussedherein disposed along either or both of the intrusion device 12 or otherselected portion of the door frame assembly 10 such as the belt-linereinforcement member 22 which is formed between the assembly and acorresponding window structure or other portion of the assembly 10suitable for application of the material 20. The material 20 is appliedover at least a portion of the intrusion device 12 or belt-line 22 inaccordance with the extrusion techniques, apparatus, and methods setforth in commonly assigned U.S. Pat. No. 5,358,397, incorporated byreference. It will also be appreciated that the material 20 may comprisepellets extruded along the intrusion device 12 and/or the belt-line 22in a variety of continuous and non-continuous patterns. In this regard,it is contemplated that technology disclosed in co-pending U.S.application Ser. No. 09/631,21 for a Sound Absorption System ForAutomotive Vehicles, incorporated by reference, may be employed in thepresent invention. FIG. 1 illustrates an example of this by showing acontinuously extruded pattern 18 of the material 20 uniformly extrudedalong the intrusion device 12. The vibration reduction material 20preferably is fixedly secured to at least one portion of the intrusiondevice 12 by one of its own external surfaces. Accordingly, it ispreferred that the vibration reduction material 20 is a polymeric foamthat includes a bonding component, which maintains it in place on theexternal surface of the intrusion device 12, and thereafter, upon heatactivation maintains its adhesion to the intrusion device 12 but expandsto form a foam within the hollow cavity between the door inner panel andthe outer panel of the selected frame assembly 10. Thus, preferably thevibration reduction material 20 is a heat-activated material having anadhesive component.

[0018] Though other heat-activated materials are possible, a preferredheat activated material is an expandable or flowable polymericformulation, and preferably one that is activate to foam, flow orotherwise change states when exposed to the heating operation of atypical automotive final assembly painting operation. A particularlypreferred material is an active polymer formulated in pellet form witheach pellet typically 1-20 mm in diameter and generally, but notnecessarily, spherical in shape to facilitate the flow of such pelletsthrough the mini-applicator more fully disclosed in commonly-owned U.S.Pat. No. 5,358,397 (“Apparatus For Extruding Flowable Materials”),incorporated by reference and other olefinic polymer-based acousticfoams, and more particularly an ethylene based polymer. For example,without limitation, in one embodiment, the polymeric foam is based onethylene copolymer or terpolymer that may possess an alpha-olefin. As acopolymer or terpolymer, the polymer is composed of two or threedifferent monomers, i.e., small molecules with high chemical reactivitythat are capable of linking up with similar molecules. Examples ofparticularly preferred polymers include ethylene vinyl acetate, EPDM, ora mixture thereof. Without limitation, other examples of preferred foamformulation that are commercially available include polymer-basedmaterial commercially available from L&L Products, Inc. of Romeo, Mich.,under the designations as L-2105, L-2100, L-7005 or L-2018, L-7101,L-7102, L-2411, L-2412, L-4141, etc. and may comprise either open orclosed cell polymeric base material

[0019] A number of other suitable materials are known in the art and mayalso be used for vibration reduction. One such foam preferably includesa polymeric base material, such as an ethylene-based polymer which, whencompounded with appropriate ingredients (typically a blowing and curingagent), expands and cures in a reliable and predicable manner upon theapplication of heat or the occurrence of a particular ambient condition.From a chemical standpoint for a thermally activated material, thevibration reducing foam is usually initially processed as a flowablethermoplastic material before curing. It will cross-link upon curing,which makes the material resistant of further flow or change of finalshape.

[0020] One advantage of the preferred vibration reduction material 20 isthat the preferred material can be processed in several ways, therebyaffording substantial design and production flexibility. For instance,without limitation, the preferred materials can be processed byextrusion techniques discussed herein, injection molding, compressionmolding, or with a mini-applicator discussed herein. This enables theformation and creation of vibration reduction shaping that exceed thecapability and maintenance/cleanliness issues of most prior artmaterials, which comprise “wet” chemistry compositions. In one preferredembodiment, the material 20 or pellet or even a plurality of pellets (inits uncured state) is generally dry or relatively free of tack to thetouch. In another embodiment, the material 20 is applied to theintrusion device 12 through a robotic extrusion process, which serves tominimize the maintenance of wet or tacky mediums and further functionsto reduce labor demand on the vehicle manufacturer.

[0021] In a particular non-limiting embodiment, the material 20 isapplied to the intrusion device 12 through the use of a mini-applicatorwhich applies heat and shear to the material 20 in accordance with theteachings of commonly-owned U.S. Pat. No. 5,358,397 (“Apparatus ForExtruding Flowable Materials”), which, in turn, transforms the material20 consisting of a plurality of pellets from a solid or dry chemicalstate to a visco-elastic state inside the mini-applicator forapplication of the material 20 to the desired surface in a desiredpattern or consistency, namely an external surface of an intrusiondevice 12 generally found in automotive vehicles, such as a doorintrusion beam.

[0022] It is contemplated that the mini-applicator prepares the material20 into a visco-elastic state which can easily and uniformly be appliedto an exterior surface of the intrusion device 12 in a relatively cleanmanner where it hardens and bonds. It will be appreciated that thematerial 20 can be applied to the intrusion device 12 in a uniformshape, thickness, or consistency which could comprise a continuous flow,a non-continuous flow, a pattern application, and even a ribbed designdepending upon the particular application and sizing found between therelated intrusion device 12 and the inner and outer panels of the chosenautomotive panel assembly. Once the mini-applicator applies the material20 to the intrusion device 12 in the desired shape and pattern, thematerial 20 cools at the ambient temperature found in the manufacturingfacility which allows the material 20 to return to its original solid ordry chemical state thereby bonding and adhering the material 20 to theexternal surface of the intrusion device 12. The intrusion device 12 isthen place mounted onto-the door assembly 10 prior to assembly of thevehicle by the vehicle manufacturer. The door assembly 10 is thenintegrated into the vehicle for application of the e-coat process aswell as other paint operation cycles commonly found in an automotivemanufacturing facility. These and paint operating cycles generallyinvolve exposure to heat through cure ovens which activate the material20 and allow it to expand, thereby chemically cross-linking the material20 on the external surface of the intrusion device 12 to either or bothof the inner door panel or the outer door panel thereby providing awalled or expansive structure which serves to reduce vibration and noiseduring transport of the vehicle and operation of the door.

[0023] While the preferred materials for fabricating the vibrationreduction material have been disclosed, the material 20 can be formed ofother materials (e.g., foams regarded in the art as structural foams)provided that the material selected is heat-activated or otherwiseactivated by an ambient condition (e.g. moisture, pressure, time or thelike) and cures in a predictable and reliable manner under appropriateconditions for the selected application. One such material is thepolymeric based resin disclosed in commonly owned, co-pending U.S.patent application Ser. No. 09/268.810 (fled Mar. 8, 1999), theteachings of which are incorporated herein by reference.

[0024] Some other possible materials include, but are not limited to,polyolefin materials, copolymers and terpolymers with at least onemonomer type an alpha-olefin, phenol/formaldehyde materials, phenoxymaterials, and polyurethane. See also, U.S. Pat. Nos. 5,266,133;5,766,719; 5,755,486; 5,575,526; 5,932,680; and WO 00/27920 (PCT/US99/24795) (all of which are expressly incorporated by reference).Examples of suitable melt flow materials include, without limitation,formulations found in a commonly owned co-pending application for aPaintable Seal System filed Aug. 7, 2000, hereby incorporated byreference. In general, the desired characteristics of the resultingmaterial include relatively low glass transition point, and goodcorrosion resistance properties. In this manner, the material does notgenerally interfere with the materials systems employed by automobilemanufacturers. Moreover, it will withstand the processing conditionstypically encountered in the manufacture of a vehicle, such as thee-coat priming, cleaning and degreasing and other coating processes, aswell as the painting operations encountered in final vehicle assembly.

[0025] In this regard, in applications where a heat activated, thermallyexpanding material is employed as the vibration reduction material, aconsideration involved with the selection and formulation of thematerial is the temperature at which a material reaction or expansion,and possibly curing, will take place. For instance, in mostapplications, it is undesirable for the material 20 to be reactive atroom temperature or otherwise at the ambient temperature in a productionline environment since, in one embodiment, the material 20 is extrudedonto the intrusion device by a supplier and then shipped to the vehiclemanufacturer as an integrated product. More typically, the material 20becomes reactive at higher processing temperatures, such as thoseencountered in an automobile assembly plant, when the material 20 isprocessed along with the vehicle components at elevated temperatures orat higher applied energy levels, e.g., during e-coat preparation stepsand other paint cycles. While temperatures encountered in an automobilee-coat operation may be in the range of about 145° C. to about 210° C.(about 300° F. to 400° F.), primer, filler and paint shop applicationsare commonly about 93.33° C. (about 200° F.) or higher. The material isthus operative throughout these ranges. If needed, blowing agentactivators can be incorporated into the composition to cause expansionat different temperatures outside the above ranges.

[0026] Generally, suitable vibration reduction materials have a range ofexpansion ranging from approximately 0 to over 1000 percent. The levelof expansion of the vibration reduction material 20 may be increased toas high as 1500 percent or more. The material may be expandable to adegree (or otherwise situated on a surface) so that individual nodesremain separated from one another upon expansion, or they may contactone another (either leaving interstitial spaces or not).

[0027] In another embodiment, the vibration reduction material isprovided in an encapsulated or partially encapsulated form, which maycomprise a pellet, which includes an expandable foamable material,encapsulated or partially encapsulated in an adhesive shell. An exampleof one such system is disclosed in commonly owned, co-pending U.S.application Ser. No. 09/524,298 (“Expandable Pre-Formed Plug”), herebyincorporated by reference.

[0028] Moreover, the vibration reduction material may include amelt-flowable material such as that disclosed in U.S. Pat. No. 6,030,701(expressly incorporated by reference).

[0029] Referring again to FIG. 1, there is shown one example of apattern 18 for the vibration reduction material 20 applied to anexternal surface of an intrusion device 12 prior to heat activation orfoaming wherein the material 20 is continuously extruded. FIG. 2illustrates a non-continuous pattern 18 of the material 20 achieved bynon-continuous extrusion. FIG. 3 illustrates the placement of thevibration reduction material along selected portions of the door frameassembly 10 which can include the belt line reinforcement 22 or othervisible or exterior portions of an automotive vehicle. The skilledartisan will appreciate that the displacement pattern of the material 20shown in FIGS. 1-3 are non-limiting examples of many patterns that maybe employed. It is contemplated that the material, after expansion, maycontain a plurality of nodes which are generally disposed in a randompattern and are generally suitable for the absorption of vibrations andother sound frequencies emanating from the door assembly or otherwisegenerated by the vehicle or its components including road induced noiseand absorb the same. In one preferred embodiment, such patterns and theselection of the material is made for achieving generally miniaturizedchamber areas, where it is believed that vibrational energy can bedissipated through the vibrational reduction material.

[0030] In addition, as discussed previously, preformed patterns may alsobe employed such as those made by extruding a sheet (having a flat orcontoured surface) and then die cutting it according to a predeterminedconfiguration in accordance with the intrusion device, and applying itthereto, wherein the extrusion may be either continuous, as shown inFIG. 1, or non-continuous, as shown in FIG. 2.

[0031] The skilled artisan will appreciate that the use of the vibrationreduction system disclosed herein is not intended as being limited onlyto illustrate the door assembly locations shown in FIG. 1. The presentinvention can be used in any location within a door or hatch entry intoan automotive vehicle that may or may not utilize an intrusion device12. For instance, other reinforced locations are also possibleincluding, but not limited to, sliding side doors, hatchbacks, rearcargo doors, gates, and crew/club cab designs and the like with orwithout the presence of an intrusion device 12.

[0032] Moreover, the skilled artisan will appreciate that the vibrationreduction system may be employed in combination with or as a componentof a conventional sound blocking baffle, or a vehicle structuralreinforcement system, such as is disclosed in commonly owned co-pendingU.S. application Ser. Nos. 09/524,961 or 09/502,686 (hereby incorporatedby reference).

[0033] A number of advantages are realized in accordance with thepresent invention, including, but not limited to, the ability tomanufacture an integrated intrusion device structure ready for deliveryand assembly at a vehicle assembly plant without the need forapplication of pumpable products, wet chemical products, and multiplesets of tools, such as for other prior art.

[0034] The preferred embodiment of the present invention has beendisclosed. A person of ordinary skill in the art would realize however,that certain modifications would come within the teachings of thisinvention. Therefore, the following claims should be studied todetermine the true scope and content of the invention.

What is claimed is:
 1. A system for the absorption of vibration in anautomotive closure panel assembly, comprising: (a) an intrusion deviceassociated with an automotive exterior panel structure; and (b) anexpandable material for absorbing vibration disposed over at least aportion of said intrusion device and in contact with said intrusiondevice prior to expansion of said expandable material, and with asurface of said panel after expansion of said expandable material. 2.The system as claimed in claim 1, wherein said intrusion device has afirst end and a second end fixedly attached to an inner portion of saidautomotive panel structure thereby defining a cavity.
 3. The system asclaimed in claim 1, wherein an external surface of said intrusion deviceis at least partially coated with said expandable material.
 4. Thesystem as claimed in claim 1, wherein said expandable material is a heatactivated thermoplastic foamable material.
 5. The system as claimed inclaim 4, wherein said expandable material comprises an extruded pellet.6. The system as claimed in claim 1, wherein said intrusion devicecomprises a door intrusion beam having an exposed surface.
 7. The systemas claimed in claim 6, wherein said exposed surface of said doorintrusion beam is suitable for application of said expandable material.8. The system as claimed in claim 1, wherein said intrusion device iscomprised of a high strength polymeric material.
 9. The system asclaimed in claim 1, wherein said expandable material is a heat activatedexpandable polymer foam.
 10. The system as claimed in claim 1, whereinsaid expandable material is an expandable ethylene based foam that isgenerally free of tack to the touch.
 11. The system as claimed in claim9, wherein said expandable material is an expandable ethylene based foamthat can be activated at a temperature encountered in an automotivevehicle paint operation.
 12. A vibration damping system for a doorassembly of an automotive vehicle, comprising: (a) an intrusion devicesuitable for fixed placement within an automotive vehicle having a firstend and a second end mounted to the door assembly defining a cavitytherein, said intrusion device further having exposed surface portionsbetween said first end and said second end; and (b) a plurality of nodesof an expandable vibration damping material in bonding contact over atleast a portion of said exposed surface portions of said intrusiondevice.
 13. The system as claimed in claim 12, wherein said expandablematerial is a polymer foam.
 14. The system as claimed in claim 12,wherein said intrusion device is a intrusion device.
 15. The system asclaimed in claim 12, wherein said expandable material is a heatactivated expandable polymer foam.
 16. The system as claimed in claim12, wherein said expandable material is an expandable polymer foam thatis generally free of tack to the touch.
 17. The system as claimed inclaim 12, wherein said expandable material is an expandableethylene-based foam that can be activated at a temperature encounteredin an automotive vehicle paint operation.
 18. The system as claimed inclaim 12, wherein said nodes include a plurality of nodes of differentsizes and shape.
 19. The system as claimed in claim 16, wherein saidexpandable material is extruded into pellets.
 20. The system as claimedin claim 16, wherein said expandable material is encapsulated.
 21. Asystem for reducing vibration in an automotive door assembly,comprising: (a) a intrusion device fixed mounted within an automotivedoor assembly; and (b) an expandable material for reducing vibrationdisposed over at least a portion of said intrusion device and in contactwith said intrusion device prior to expansion of said expandablematerial.
 22. The system as claimed in claim 21, wherein said intrusiondevice defines a cavity of an automotive door assembly.
 23. The systemas claimed in claim 21, wherein said intrusion device is at leastpartially coated with said expandable material.
 24. The system asclaimed in claim 21, wherein said expandable material is a heatactivated thermoplastic foamable material.
 25. The system as claimed inclaim 24, wherein said expandable material comprises an extruded pellet.26. The system as claimed in claim 21, wherein said intrusion deviceincludes an exposed surface.
 27. The system as claimed in claim 26,wherein said exposed surface of said intrusion device is suitable forapplication of said expandable material.
 28. The system as claimed inclaim 21, wherein said intrusion device is an automotive intrusion beam.29. The system as claimed in claim 21, wherein said expandable materialis a heat activated expandable polymer foam.
 30. The system as claimedin claim 21, wherein said expandable material is an expandable ethylenebased foam that is generally free of tack to the touch.
 31. The systemas claimed in claim 29, wherein said expandable material is anexpandable ethylene based foam that can be activated at a temperatureencountered in an automotive vehicle paint operation.